Hot swap battery pack

ABSTRACT

A battery module may include a rectangular tower comprised of four longitudinal faces, a top face, and a bottom face; one or more battery cells disposed inside the rectangular tower; chamfered edges disposed around a perimeter of the bottom face, the chamfered edges reducing a perimeter of the bottom face as the chamfered edges extend downwards towards at an extreme end of the bottom face; and a battery module connector disposed adjacent the extreme end of the bottom face recessed from the extreme end of the bottom face and at least partially shrouded by the chamfered edges, the battery module connector including or having formed thereon one or more alignment pins or one or more alignment pins receivers and one or more electrical contacts.

RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationNo. 63/242,819, filed on Sep. 10, 2021, and titled “BATTERY SYSTEM ANDBATTERY POWERED VEHICLE,” the entirety of which is incorporated hereinby reference.

TECHNICAL FIELD

The present invention relates to swappable battery packs and anassociated battery port for electric vehicles.

BACKGROUND

Electric vehicles continue gaining traction as a means oftransportation. Light electric vehicles (LEV) specifically, are gainingtraction in the United States after enjoying years of popularity inEurope. Part of the appeal is the ease of ride. Most people can ridethem, from the most seasoned rider to someone who has not ridden sincechildhood. LEV have the potential to expand riding to new audiences andkeep people riding throughout their lives.

As cities continue to expand the need for accessible and affordabletransportation expands as well. LEV have been growing in popularity tofill this need. However, these vehicles need to be recharged regularlywhich puts infrastructure constraints and risks that a person's ride mayend prematurely if the battery on the vehicle dies mid use. There is aneed for a battery configuration that is easily accessible for removingand replacing so a user can always have access to a full battery.

SUMMARY

At least one aspect of the present disclosure aims to overcome thedeficiencies of conventional battery packs. At least one aspect of thepresent disclosure overcomes the deficiencies of conventional batterypacks by having a multi-faceted securing means for ensuring properconnection of the battery pack in the battery connection port. Anotheraspect of the present disclosure overcomes the deficiencies inconventional electric vehicle battery configurations by having an easilyaccessible battery pack that can be easily handled and removed when thebattery is depleted, then replaced with a charged battery when needed.

The following description and the annexed drawings set forth certainillustrative embodiments of the invention. These embodiments areindicative, however, of but a few of the various ways in which theprinciples of the invention may be employed. Other objects, advantages,and novel features according to aspects of the invention will becomeapparent from the following detailed description when considered inconjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The annexed drawings, which are not necessarily to scale, show variousaspects of the invention.

FIG. 1 illustrates a perspective view of an exemplary batteryconfiguration in accordance with some aspects of the present disclosure.

FIG. 2 illustrates a perspective view of an exemplary battery module inaccordance with some aspects of the present disclosure.

FIG. 3 illustrates a bottom view of an exemplary battery module inaccordance with some aspects of the present disclosure.

FIG. 4 illustrates a perspective view of an exemplary battery base inaccordance with some aspects of the present disclosure.

FIG. 5 illustrates a top view of an exemplary battery base in accordancewith some aspects of the present disclosure.

FIG. 6 illustrates a perspective view of an exemplary batteryconfiguration in accordance with some aspects of the present disclosure.

FIG. 7 illustrates a light electric vehicle (LEV) with an associatedexemplary battery configuration in accordance with some aspects of thepresent disclosure.

FIG. 8 illustrates a block diagram of an exemplary battery module inaccordance with some aspects of the present disclosure.

DETAILED DESCRIPTION

The principles and aspects of the present disclosure have application tolight electric vehicles (LEV), and thus will be described below chieflyin this context. It is understood, however, that the principles andaspects of the present disclosure may be applicable to other electricvehicle applications as well as for any other application that requireselectric energy where a removable battery module would be beneficial.Battery pack and battery module may be used interchangeably throughoutthe present disclosure.

FIG. 1 illustrates an exemplary battery configuration 10 in accordancewith embodiments of the present disclosure. The battery configuration 10includes a battery module 12 and a base 14.

In one exemplary embodiment, the base 14 may be a stand-alone chargingport as depicted in FIGS. 4-6 while in another exemplary embodiment thebase 14 may be a vehicle battery dock or receiver as depicted in FIG. 7.

FIGS. 1-5 illustrate a first embodiment of the battery configuration 10while FIG. 6 illustrates a second embodiment of the batteryconfiguration 10.

The battery module 12 may be configured as a rectangular tower with fourlongitudinal faces 50 and four chamfered longitudinal edges 52. Thebattery module 12 further includes a top surface or face 54 and a bottomsurface or face 56. The top surface may have a handle 60 installed orformed thereon. The handle 62 may be configured along the top surface 54of the battery module 12. The handle 62 may be secured directly to theface of the top surface 54 or to one of the longitudinal faces 50. Thehandle 62 may be secured to the battery module 12 by fasteners 64 or byother securing means such as welding or a slot and pin configuration.The handle 62 provides a handhold for a user to easily hold the batterymodule 12 for removal and installation of the battery as well as fortransportation of the battery module 12.

The battery module 12 may be comprised of a metal casing such asaluminum or other lightweight metal. The battery module 12 may also becomprised of a lightweight and durable polymer.

The weight, size, and form factor of the module 10 is designed withergonomics in mind to be “human-sized.” That is, the module 10 may bedesigned to be pluggable/unpluggable and transportable by a singleperson: of such size, shape, and weight that a single person may carryit relatively comfortably and without injury.

Regarding weight, the module may be designed to comply with maximumlifting weight regulations or guidelines such as, for example, theRevised National Institute of Occupational Safety and Health (NIOSH)Lifting Equation (2021), guidelines for evaluating two-handed manuallifting tasks. Such guidelines define a Recommended Weight Limit (RWL)as the weight of the load that nearly all healthy people (typicallyworkers) can lift over a substantial period of time (e.g., eight hours)without an increased risk of developing lower back pain.

Regarding size and form factor, the module 10 may be designed to have agenerally “suit case” rectangular form factor with the handle 22installed or built thereupon at one end of the module 10. The dimensionsof the module 10 may be height in the range of 12 inches to 24 inches,width in the range of 6 inches to 12 inches, and depth in the range of 4inches to 8 inches. In one embodiment, the module 10 may be 16 inchestall, 9.5 inches wide, and 5.5 inches deep. In some embodiments, thebattery module 10 is designed with height in a range shorter than 12inches or taller than 24 inches, width in a range narrower than 6 inchesor wider than 12 inches, and depth in a range shallower than 4 inches ordeeper than 8 inches.

The bottom face 56 may include a module connector 58 disposed adjacentthe bottom of the battery module 12 but recessed from the bottom of thebattery module and at least partially shrouded by chamfered edges 22 toprotect the module connector when the battery module 12 is, for example,being transported. The chamfered edges 22 are disposed around aperimeter of the bottom face 56. The chamfered edges 22 reduce aperimeter of the bottom face 56 as the chamfered edges extend downwardstowards at an extreme end of the bottom face 56. The chamfer of theedges 22 correspond to the chamfer of the sidewalls 32 of the base 14.

The battery module connector 58 may include one or more alignment pinreceivers 24 and one or more module contacts 26, which may correspond topower transfer contacts and data transfer contacts which are configuredas conductive metal contact points for the transfer of electric currentor signals. The one or more alignment pin receivers 24 and the one ormore module contacts 26 correspond to alignment pins 36 and one or morebase contacts 38 of the base connector 33.

The battery base 14 includes a battery module seat 28, sidewalls 32 thatextend for the battery module seat 28 and which are chamfered, and theconnector 33. Walls of the connector 33 may also be chamfered as toinvite the matching battery module connector 58 into smooth and reliableconnection. The battery module 12 rests on the battery module seat 28when installed. The alignment pins 36 extends upwards from the batterymodule seat 28. The alignment pins 36 correspond to the alignment pinreceivers 24 in the battery module 12. The battery module seat 14includes one or more contact pin receivers 38. The contact pin receivers38 correspond to the contact pins 26.

In one embodiment, instead of one or more alignment pin receivers 24,the battery module connector 58 includes one or more alignment pins and,instead of one or more alignment pins, the base connector 33 includesone or more alignment pin receivers.

In the embodiment of FIG. 7 , the battery module 12 has formed thereonone or more guide rails or slots 20 extending along a longitudinal face50 of the battery module 12. The guide slots 20 may be configured as achannel or recess in the one or more longitudinal faces 50. In thisembodiment, the vehicle battery receiver or base 14 has formed thereoncorresponding one or more guide tabs 30 for interfacing with the one ormore guide rails 20.

The guide slots 20, alignment pins 36, and chamfered edges 22, 32 serveas a multi-faceted means of securement to ensure that the battery module12 is secure in the vehicle battery receiver or base 14.

The alignment pin receivers 24 may be configured as recesses in thebottom surface 56. The recesses may include a locking mechanism such asa spring biased pin to secure the one or more alignment pins 36 in theone or more alignment pin receivers.

The battery module 12 may include one or more battery cells electricallyorganized to enable delivery of targeted range of voltage and currentfor a duration of time against expected load scenarios. The number andcapacity of the battery cells may vary depending on the application. Thebattery cells may be, for example, lithium-ion rechargeable cell, butmay be other types of rechargeable cells.

In the embodiment of FIG. 7 , the base connector 33 may also bechamfered. The connector 33 a chamfered guide 70 corresponding to arecess 72 in the battery module 12.

In one embodiment, the battery configuration 10 further includes asafety switch 40 which is engaged only when the battery module 12 isfully seated into the battery base 14 or when the battery moduleconnector 58 is fully connected to the base connector 33.

In an exemplary embodiment, the safety switch 40 may be a mechanicalswitch that engages and secures the battery module 12 in the batterybase 14. The mechanical switch 40 may be a spring biased pin engagementfeature that secures the battery module 12 in place until the userreleases the pin. Other mechanical means of securing the battery module12 in the battery base 14 may be suitable. In another exemplaryembodiment, the safety switch 40 may be an electrical switch. When thebattery module 12 is fully connected to the battery base 14 anelectrical signal may be sent to the vehicle's control interface whichactivates a signal notifying the operator that the battery module 12 isfully seated into the battery base 14.

In an exemplary embodiment as shown in FIG. 7 , the vehicle 2 mayinclude a securement lid 15 pivotable over the vehicle battery port 14.The securement lid 15 may be pivoted or otherwise made to engage thebattery module 12 such that the battery module 12 is secured in thevehicle battery port 14. The underside of the securement lid 15 mayinclude a means of dampening vibration such as foam or other softmaterial to ensure that the battery module 12 does not vibrate out ofthe vehicle battery port 14 during operation of the vehicle 2.

FIG. 8 illustrates a block diagram of an exemplary battery module 10.The battery module 10 may include one or more battery cells 13, one ormore module processors 15, a battery management system (BMS) 17, awireless transceiver 19, a power port 25, and a data port 27.

The battery module 10 may include the one or more battery cells 13electrically organized to enable delivery of targeted range of voltageand current for a duration of time against expected load scenarios. Thenumber and capacity of the battery cells may result in various capacitylevels for the battery module 10. The battery cells 12 may be, forexample, lithium-ion rechargeable cells, but may be other types ofrechargeable cells.

The battery module 10 may include one or more module processors 15operably connected to the one or more battery cells 13 to obtainperformance information from the one or more battery cells 13. Theprocessor 14 may be operably connected to the battery cells 13 via thebattery management system (BMS) 17. The BMS 17 may perform oversight ofthe battery cells 13 including, for example, monitoring parameters(e.g., voltage, current, temperature, etc.), providing batteryprotection (e.g., overcurrent, short circuit, over-temperature, etc.),preventing operation outside a battery cell's ratings, estimating abattery cell's operational state, continually optimizing batteryperformance, reporting operational status to the processor 15, etc. Theprocessor 15 is operably connected to the BMS 16 to obtain theperformance information of the battery cells 13.

The battery module 10 may also include a wireless transceiver 19operably connected to the processor 15 to remotely transmit dataincluding the performance information from the battery cells 13. Thewireless transceiver 19 may include a transmitter, a receiver, or bothand, thus, it may exclusively transmit information, exclusively receiveinformation, or it may transmit and receive information. The wirelesstransceiver 19 may be a broadband cellular network (e.g., 3G, 4G, 5G,etc.) transceiver or a transceiver employing other local area network(LAN) or wide area network (WAN) technologies. The wireless transceiver19 may, for example, communicate in a network using Wi-Fi, Bluetooth,satellite communication, etc.

The battery module 10 may include a power port 25 for connecting thebattery module 10 to a base 14 of a powered device such as the vehicle2. The powered device may also correspond to any other battery powereddevice such as a home appliance, etc. The power port 25 may also serveas a recharge port for the battery module 10.

The battery module 10 may also include a data port 27 to connect thebattery module 10 to a data buss of the powered device. For example, ifthe powered device is a vehicle, the data port 27 may be connected to aCAN bus (ISO 11898 Standard) of the vehicle. Similarly, the data port 27may be connected to other communications systems such as, for example,wired standard (RS485, etc.) as well as wireless standard (Wi-Fi,Bluetooth, ZigBee, WiMax, etc.) communications systems. Thus, the dataport 27 may be wired port, a wireless port, or combinations thereof.

The connector 58 plugs into the connector 3 of the base 14. Theconnector 58 may incorporate the power port 25 and data port 27. Thebase 14 may be a stand-alone charging/power distribution port connectedto a building's power distribution system. The base 14 may also be avehicle battery dock or receiver for the vehicle 2.

The battery module 10 may also include a global position system (GPS) 29receiver operably connected to the processor 15 to communicate to theprocessor 15 a geographical location of the battery module 10. In someembodiments, the battery module 10 may employ techniques (e.g.,Bluetooth communication with GPS-equipped mobile phone, Wi-FiPositioning System (WPS), etc.) instead of or in addition to the to theGPS 29 to obtain the geographical location of the battery module 10.

In one embodiment, the base 14 or a device (e.g., vehicle 2, appliance,etc.) may include a processor 31 that communicates with the processor 15via the data port 27. In one embodiment, the processor 15 questions theprocessor 31 for a certain code or other authenticating credentials forthe battery module 10, as well as any other identifying information(e.g., model number, power level, date of manufacture, serial number,etc.) This way, the powered device 2 may make certain the battery beingplugged in to provide power is safe and genuine.

In one embodiment, the battery module 10 may be required to sign in viaa certain code or other authenticating credentials wirelessly via thewireless transceiver 19. The base 14 may be configured to not acceptpower from the battery module 10 until authorized by a remote server ora mobile phone. The wireless transceiver 19 may establish wirelesscommunication with the remote server or mobile phone for the processor15 to communicate the certain code or other authenticating credentialsto the remote server or mobile phone.

In certain embodiments, battery module 10 authentication as describedabove may be initiated automatically upon connection of the connectors58 to 33 or upon wireless proximity detection of the battery module 10to the base 14.

Definitions

The following includes definitions of selected terms employed herein.The definitions include various examples or forms of components thatfall within the scope of a term and that may be used for implementation.The examples are not intended to be limiting. Both singular and pluralforms of terms may be within the definitions.

An “operable connection,” or a connection by which entities are“operably connected,” is one in which signals, physical communications,or logical communications may be sent or received. Typically, anoperable connection includes a physical interface, an electricalinterface, or a data interface, but it is to be noted that an operableconnection may include differing combinations of these or other types ofconnections sufficient to allow operable control. For example, twoentities can be operably connected by being able to communicate signalsto each other directly or through one or more intermediate entities likea processor, operating system, a logic, software, or other entity.Logical or physical communication channels can be used to create anoperable connection.

To the extent that the term “includes” or “including” is employed in thedetailed description or the claims, it is intended to be inclusive in amanner similar to the term “comprising” as that term is interpreted whenemployed as a transitional word in a claim. Furthermore, to the extentthat the term “or” is employed in the detailed description or claims(e.g., A or B) it is intended to mean “A or B or both.” When theapplicants intend to indicate “only A or B but not both” then the term“only A or B but not both” will be employed. Thus, use of the term “or”herein is the inclusive, and not the exclusive use. See, Bryan A.Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995).

While example systems, methods, and so on, have been illustrated bydescribing examples, and while the examples have been described inconsiderable detail, it is not the intention of the applicants torestrict or in any way limit scope to such detail. It is, of course, notpossible to describe every conceivable combination of components ormethodologies for purposes of describing the systems, methods, and soon, described herein. Additional advantages and modifications willreadily appear to those skilled in the art. Therefore, the invention isnot limited to the specific details, the representative apparatus, andillustrative examples shown and described. Thus, this application isintended to embrace alterations, modifications, and variations that fallwithin the scope of the appended claims. Furthermore, the precedingdescription is not meant to limit the scope of the invention. Rather,the scope of the invention is to be determined by the appended claimsand their equivalents.

1. An electric vehicle comprising: a battery module having a batterymodule connector disposed adjacent a bottom of the battery modulerecessed from the bottom of the battery module and shrouded by chamferededges disposed around the perimeter of the bottom of the battery module,the battery module connector comprising one or more alignment pins oralignment pin receivers and one or more module contacts recessed withinthe battery module connector; and a vehicle battery receiver having avehicle battery connector disposed on the vehicle facing generallyupwards for receiving the battery module, the vehicle battery connectorat least partially shrouded by chamfered sidewalls corresponding to thechamfered edges and disposed at least partially around a perimeter ofthe vehicle battery receiver, one or more alignment pins or alignmentpin receivers which correspond to the one or more alignment pinreceivers or alignment pins of the battery module connector, and one ormore vehicle contacts corresponding to the one or more module contacts.2. The electric vehicle of claim 1, wherein the battery module connectoris disposed at a center of the bottom of the battery module and thevehicle battery connector is disposed at a center of the vehicle batteryreceiver.
 3. The electric vehicle of claim 1, wherein the battery moduleis comprised of a rectangular tower comprised of four longitudinalfaces, four chamfered longitudinal edges, a top face, and a bottom face.4. The electric vehicle of claim 1, wherein the battery module includesone or more handles.
 5. The electric vehicle of claim 4 wherein the oneor more handles are fastened to the battery module.
 6. The electricvehicle of claim 1, wherein the battery module has formed thereon one ormore guide rails extending along a longitudinal length of the batterymodule, and the vehicle battery receiver has formed thereoncorresponding one or more guide tabs for interfacing with the one ormore guide rails.
 7. The electric vehicle of claim 1, wherein thealignment pin receiver is a recess in the bottom surface of the batterymodule.
 8. The electric vehicle of claim 7 wherein the recess includes aspring biased pin securing mechanism.
 9. The electric vehicle of claim1, wherein the battery module is comprised of a metal casing, such asaluminum.
 10. The electric vehicle of claim 1, comprising a safetyswitch disposed on the battery module or the electric vehicle body,wherein the safety switch is engaged to indicate the battery moduleconnector is fully connected to the battery vehicle connector.
 11. Theelectric vehicle of claim 10, wherein the safety switch activates asignal which sends a connection confirmation to a control interface inthe electric vehicle to indicate the battery module connector is fullyconnected to the battery vehicle connector.
 12. The electric vehicle ofclaim 1, wherein the electric vehicle includes a securement lid tosecure the battery module connected to the electric vehicle.
 13. Theelectric vehicle of claim 12, wherein the securement lid includes avibration dampener.
 14. A battery module comprising: a rectangular towercomprised of four longitudinal faces, a top face, and a bottom face; oneor more battery cells disposed inside the rectangular tower; chamferededges disposed around a perimeter of the bottom face, the chamferededges reducing a perimeter of the bottom face as the chamfered edgesextend downwards towards at an extreme end of the bottom face; and abattery module connector disposed adjacent the extreme end of the bottomface recessed from the extreme end of the bottom face and at leastpartially shrouded by the chamfered edges, the battery module connectorincluding or having formed thereon one or more alignment pins or one ormore alignment pins receivers and one or more electrical contacts. 15.The battery module of claim 14, wherein one or more of the fourlongitudinal faces have formed thereon a guide slot or guide railextending a length of the one or more of the four longitudinal faces.16. The battery module of claim 14, comprising a safety switch disposedon the battery module, wherein the safety switch is engaged to indicatethe battery module connector is fully connected to a battery vehicleconnector.
 17. The battery module of claim 16, wherein the safety switchactivates a signal which sends a connection confirmation to a controlinterface in the electric vehicle to indicate the battery moduleconnector is fully connected to the battery vehicle connector.
 18. Thebattery module of claim 14, wherein the battery module connector isdisposed at a center of the bottom face of the battery module.
 19. Thebattery module of claim 14, wherein the battery module includes one ormore handles.
 20. The battery module of claim 19, wherein the one ormore handles are fastened to the battery module.